Operator's Manual

TL165
Operator's manual
3
1. Foreword ............................................................................................................................... 5
1.1. About the Operator's manual .................................................................................................................... 5
1.2. About the documentation kit ..................................................................................................................... 7
1.3. Inspection and maintenance ..................................................................................................................... 8
2. Safety ..................................................................................................................................... 9
2.2. Safety and warning equipment ................................................................................................................. 10
3. Overview ............................................................................................................................... 13
3.1. Description ................................................................................................................................................... 13
4. Instruments and controls .................................................................................................... 17

4.2. Ignition .......................................................................................................................................................... 22
4.3. Gear and multi-function lever ................................................................................................................... 24
4.4. Control lever ................................................................................................................................................ 28
4.5. Pedals ........................................................................................................................................................... 29
4.6. Operator's seat ............................................................................................................................................ 30
4.7. Heating / Air conditioning .......................................................................................................................... 31
5. Handling ................................................................................................................................ 33
5.2. Running-in ................................................................................................................................................... 34
5.3. Daily inspections ......................................................................................................................................... 35
5.4. Handling error codes .................................................................................................................................. 36
5.5. Operating ..................................................................................................................................................... 37
5.6. Load handling .............................................................................................................................................. 42
6. Inspection and maintenance ............................................................................................... 45

6.2. Daily inspection ........................................................................................................................................... 46
6.3. Maintenance ................................................................................................................................................ 48
6.4. Service ......................................................................................................................................................... 54
7. Transport of machine ........................................................................................................... 61

7.1. Towing .......................................................................................................................................................... 61
7.2. Lifting and transporting machine .............................................................................................................. 63
7.3. Service position ........................................................................................................................................... 64
7.4. Long-term storage ...................................................................................................................................... 65
8. Environment ......................................................................................................................... 67
9. Specifications ....................................................................................................................... 75
Index .......................................................................................................................................... 83
4
1 Foreword 5
1 Foreword
1.1 About the Operator's manual
General
Read the operating instructions in this manual carefully, and follow
them strictly when operating the machine so that the safety and reli-
ability of the machine will be maintained.
Contact your superior if some parts of this manual lead to questions
or some important information seems to be missing.
We thank you for selecting Kalmar as the provider of your machine.
We believe that we can fulfil your expectations with regard to the op-
erational features and availability of maintenance services.
Operating policy
The business philosophy of Cargotec Asia Limited is, based on the
customer's needs, requirements, and expectations, to develop, man-
ufacture, and provide products and associated services in a way that
always ensures the full satisfaction of our customers.
Plant management utilizes a certified quality system in compliance
with the ISO 9001:2008, ISO 14001:2004 and OHSAS 18001:2007
standards.
Storage
Keep the manual in good condition, and store it in a place where it is
always available to the operator or service personnel.
Copyright
This document may not be copied, presented, or delivered to a third
party without our explicit permission, or used for purposes other than
those allowed by us.
We reserve the right to alter the adjustment values, equipment, and
service and repair instructions for the machine without prior notice.
Cargotec Asia Limited
1.1.1 Reading the manual

Information on possible safety hazards
This manual includes three types of warnings containing instructions
on how to avoid situations that may compromise the safety of opera-
tions.
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6 1 Foreword - 1.1.1 Reading the manual
DANGER
Warns about a situation that involves an immediate risk
of personal injury or death unless the safety
instructions indicated are observed.
WARNING
Warns of a situation that may cause personal injury,
death, and/or substantial damage to the machine or
other property unless the safety instructions provided
are observed.
CAUTION
Warns about a situation that may cause moderate
personal injury and/or damage to the product or other
property if the safety instructions provided are not
observed.
Important information
The word NOTE is used to emphasize aspects of the machine's
operational safety or operation instructions that the driver must
pay particular attention to when working with the machine.
An example of how the word NOTE appears is presented below.
NOTE
Calls the reader's attention to an instruction that, e.g., emphasizes
operational safety.
Optional equipment
The machine can be equipped with various accessories or optional
equipment. The equipment is marked with the symbol seen on the
left. The symbol is always accompanied by text representing and de-
The symbol indicates an accessory or optional scribing the equipment.
equipment. The symbol is clearly distinguished from the text, and it is placed next
to the text and picture representing the equipment.
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1 Foreword - 1.2 About the documentation kit 7
1.2 About the documentation kit
Manual package
The following manuals are included with the machine delivery as or-
dered:
• Operator’s manual
• Spare parts catalogue
If extra copies of instruction manuals or the spare parts catalogue for

the machine are needed, they can be ordered separately.
Ordering the manuals

The manuals can be ordered from manufacturer's spare parts depart-
ment.
Refer to the type and serial number of the tractor when placing the
order.
Operator's manual
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8 1 Foreword - 1.3 Inspection and maintenance
1.3 Inspection and maintenance
General
Chapter 6, Inspection and maintenance, contains instructions on
daily inspection and maintenance tasks that must be carried out
at the beginning of each shift.
Maintenance
Regular maintenance is carried out according to the maintenance
programme defined in the Chapter 6, Inspection and mainte-
nance.
The recommended service items and instructions are specified in
the Chapter 6, Inspection and maintenance.
Do not hesitate to contact the maintenance staff of the manufac-
turer or an authorised service outlet if you need further information
on maintenance.
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2 Safety 9
2 Safety
General
This chapter contains general instructions for the driver to ensure that
the machine is used safely and as intended. Safety instructions on
use and maintenance of the machine can also be found in the chapters
of the manual concerning these subjects.
• Carefully study the operating instructions and the functioning of
the control devices. Do not use the machine if you are not familiar
with the instructions and regulations concerning its safe operation.
If required, ask your supervisor for guidance.
• Clean the machine regularly to ensure correct and safe operation.
• Regularly perform all maintenance according to the programme
defined in the Chapter 6. Professionally performed maintenance
ensures that the machine operates safely and as intended.
• When the machine is in use, passenger transport is not allowed,
except for the occupational training carried out by the supervisor.
• Notify your superior or the person responsible for the maintenance

of the machine IMMEDIATELY of any malfunctions or other re-
pairs that are necessary.
• OBSERVE any site-specific work and safety instructions on the
operation of the machines in addition to the instructions in this
manual.
WARNING
NEVER USE OPEN FLAME TO CHECK THE FLUID
LEVEL IN THE FUEL TANK AND/OR BATTERY TO
PREVENT THE RISK OF ACCIDENT DUE TO
EXPLOSIVE IGNITION OF FUEL FULMES AND/OR
SULPHURIC ACID!
WARNING
ALWAYS TURN OFF THE ENGINE BEFORE
REFUELING TO PREVENT INJURY OR PROPERTY
DAMAGE DUE TO FUEL ACCIDENTLY SPILLED ON
HOT ENGINE COMPONENTS!
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10 2 Safety - 2.1 Safety and warning equipment
2.1 Safety and warning equipment
General
This chapter describes safety instructions concerning operation of
the terminal tractor. While operating the terminal tractor strictly
follow the general instructions on the safe operation of the ma-
chine in section 2.
Tilting the cab for maintenance

• Prior to tilting the cab to the maintenance position, ensure that
the cab door is properly closed and any loose items are re-
moved from the cab.
• Prior to lowering the cab, check that the cab path is free of ob-
structions .
• If the tilting hydraulics hoses or fittings are to be replaced, use
only original spare parts and accessories available from our spare
parts department.
DANGER
Working under the cab without the mechanical safety
stop that prevents the cab from lowering is strictly
prohibited!
Belts and driveshafts
DANGER
When checking the operation of a running engine with
the cab tilted to the maintenance position, pay special
attention to the rotating belts and driveshafts.
Pieces of clothing can be easily caught in a rotating
part and, when wrapped and tightened around the part,
may cause personal injury!
Driving speed
• The maximum driving speed of the terminal tractor is to be
used ONLY when driving straight on a smooth surface.
• ALWAYS decrease driving speed prior to turning the terminal
tractor or driving on an inclined surface, and ALWAYS when
visibility is limited.
• While driving the terminal tractor, avoid sudden braking and
acceleration and drive slowly when cornering.
• Always drive slowly when coupling the terminal tractor's fifth
wheel to the trailer to be moved. This applies also to uncoupling
the trailer from the fifth wheel to avoid damaging the equip-
ment.
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2 Safety - 2.1 Safety and warning equipment 11
Parking brake
• When leaving the terminal tractor cab, set the driving direction se-
lector to neutral and always engage the parking brake.
• If the parking brake has been released mechanically due to, for
example, towing, work with the terminal tractor may not be re-
sumed until the braking system is restored to working condition.
Fifth wheel and lift boom

• Tow a load only when the kingpin is locked.
The green indicator light on the dashboard panel is illuminated
when the kingpin is locked.
• Never go near a loaded terminal tractor if the fifth wheel is up.
• Always turn the main switch to the off position for repairing the
lift boom and fifth wheel.
• The fifth wheel must be unloaded and the lift boom must be sup-
ported mechanically if the lift boom needs to be in the upper po-
sition during repair.
• Prior to lowering the lift boom, check that its path is free of ob-
structions and any mechanical supports, etc. are removed from
between the terminal tractor frame and lift boom.
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12 2 Safety - 2.1 Safety and warning equipment
Operator's manual
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3 Overview 13
3 Overview
3.1 Description
About models
The two-wheel drive TT terminal tractors are designed mainly for
moving trailers at locations with relatively level surfaces.
The four-wheel drive TR models are designed mainly for ro-ro-appli-
cations in ports where a powerful machine is required for loading ships
by pushing and pulling loads up on ramps.
We also manufacture terminal tractors for industry to meet their in-
plant cargo transportation needs.
In case terminal tractors should be used for other applications than
those described above, it must be approved by the manufacturer in
writing.
3.1.1 Main components

General
3 4 8 5
This chapter describes the location of the terminal tractor main com-
ponents indicated in the picture below as well as a general description
of these components and their operation.
1. Cab
2. Engine
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14 3 Overview - 3.1.1 Main components
3. Steering axle
4. Transmission
5. Rear axle
6. Fifth wheel
7. Lift boom
8. For LHD hydraulic oil tank on the left side and fuel tank on the
right side.
For RHD hydraulic oil tank on the right side and fuel tank on
the left side.
Engine
Engine is low-emission six-cylinder turbocharged diesel engine
with intercooler. The engine drives the transmission, hydraulic and
pneumatic systems.
The terminal tractor is equipped with the following engine:
• DongFeng Cummins QSB6.7-C220
Transmission
• The transmission Allison 3500 features four speeds for forward
and one for reverse.
• The transmission is equipped with cab-mounted pushbutton
type shift selector.
Rear axle
The drive axle (rear axle) is equipped with solid mounting, drum
brakes, differential, central speed reducer, wheel side speed re-
ducer, wheel hub and planetary drive.
Front axle
The front axle is equipped with spring suspension, drum brakes,
steering joint and wheel hub.
Brakes
TL165 tractor axles are equipped with pneumatic brake system,
which consists of two parts: foot brake and spring parking brake.
Foot brake is controlled by foot pedal valve (pedal) located in
steering room. Pedal pressure is directed to brake, and the amount
of pedal pressure determines the amount of brake pressure. That
means the greater the pedal pressure is, the stronger the force on
brake will be.
Spring brakes are used to park the tractor. Besides, the controller
in parking brake can actuate spring brakes, so spring brakes are
called as parking brake. Spring brakes are activated by means of
spring mechanical force. During this process, air is not necessary,
but de-aeration is needed. When the driver engages the spring
brakes or when the brake system air pressure drops below the set
minimum pressure (43 P.S.I.), spring brakes will activate auto-
matically. It is released by compressed air when air pressure is
recovered to certain value (70 P.S.I.).
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3 Overview - 3.1.1 Main components 15
Lift boom
The lift boom is attached to the terminal tractor frame at its front end
with two pivot pins. The lift boom rear end is attached with pivot pins
to the single or double-acting lift cylinders. The lift cylinders are at-
tached to the terminal tractor frame with pivot pins.
Fifth wheel
The fifth wheel is attached to the lift boom with two pivot pins. Kingpin
unlocking is actuated with a pneumatic cylinder. In case of a pneu-
matic system malfunction, the kingpin locking can be released with
the mechanical lever at the fifth wheel.
The terminal tractor is equipped with the following fifth wheel:
• Land H3510
• Holland series
Fuel tank
Fuel tank capacity is 75GL (283 litres). For LHD, the location of the
tank is on the right side. And for the RHD, the location of it is on the
left side.
Hydraulic oil tank

Hydraulic oil tank capacity is 60 litres. As standard assembly the tank
is equipped with sight glass for oil level, return flow filter and tank
breather filter. Both filters have replaceable filter elements.
For LHD, the location of the tank is on the left side. And for the RHD,
the location of it is on the right side.
Hydraulic system
For stationary fifth wheel, the hydraulic power used in steering derive
from the pump of engine. The pump was cancelled for elevating fifth
wheel.
The pressure and volume flow required by the terminal tractor hy-
draulic system is generated by a fixed pump which is actuated by the
PTO - on the transmission.
A priority valve is integrated in the pump and it primarily directs the
pump output for the tractor steering. The flow for the steering is de-
termined by the load information coming from the steering device. If
steering is not in operation, no hydraulic oil flow is directed to the
steering cylinders.
Electric system
The electric system voltage is 24 Vdc. While the engine is running,
the batteries are charged by the alternator coupled to the engine.
The main switch is located near the batteries. When the main switch
is in the Off position, power supply to the electric system is totally shut
off. The main switch is not to be turned off while the engine is running
since the alternator supplies power to the electric system and the
electric components can be damaged by overvoltage.
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16 3 Overview - 3.1.1 Main components
Pneumatic system
Compressed air is supplied by a continuously operating compres-
sor which draws the air through the engine air filter. System pres-
sure is controlled by a pressure control valve which directs the
compressor output to the bypass line when the system pressure
reaches the set maximum.
Moisture is removed from the compressed air by an air dryer.
Trailer connecting
The pneumatic connection between the terminal tractor and a
trailer:
• Fixed glad hand connections, double line system, red and blue.
Connectors are located on a bracket near the cab roof edge.
Cab
The cab can be tilted to the maintenance position. The cab is con-
nected to the frame by means of two rubber mounts at the front
and one air-suspended mount at the rear. Cushioned cab mount-
ing, large window area, interior heater, and optional air condition-
ing provide a quiet and pleasant working environment.
From the cab, the driver has excellent visibility in the driving di-
rection and to the entire working area of the terminal tractor. Con-
trols for the terminal tractor and any equipment attached to it are
ergonomically positioned on the steering column, dashboard pan-
els.
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4 Instruments and controls 17
4 Instruments and
controls
General
This chapter contains general information about the terminal tractor
controls. All controls required for operating the tractor are located in
the cab.
The controls consist of various steering devices, a display panel,
switches, and pedals.
Study the location and operation of all controls carefully prior to com-
mencing work with the tractor.
If you need additional information about the operation of the controls,
do not hesitate to ask your supervisor or a person responsible for
maintenance of the tractor.
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18 4 Instruments and controls
Location of controls in the cab
1 2 3
4 5 6 7 8 9
List of controls
1. Steering column, detailed description on the following pages
2. Dashboard panels, detailed description on the following pa-
ges
3. Driving direction selector, detailed description on the following
pages
4. Brake pedal
5. Accelerator pedal
6. Trailer air supply
7. Parking brake
8. Fifth wheel control
9. Fifth wheel lock control
Operator's manual
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Steering column
Steering column switch
This switch operates the turn signals (2). The button on the end of
the arm operates the high beam lights (1) (the headlights must be
on.) The pull out switch located just underneath of the arm operates
the emergency flashers (3).
1 2 3
Dashboard panel
Gauges and switches
1. Headlight / running light switch.This switch operates the head-
1 2 3 4 lights and running lights on the tractor and trailer. This switch also
turns on the interior dash and gauge lights when either the head-
lights or running lights are turned on. This switch has three po-
sitions: Off, Running lights on and Running lights and headlights
on.
2. Fuel gauge. This gauge indicates the amount of fuel in the fuel
tank.
3. Oil pressure gauge.This gauge indicates the engine oil pres-
sure in MPa.
4. Water temperature gauge.This gauge indicates the tempera-
ture of the engine coolant in degrees Celsius.
5. Speedometer. This gauge indicates the operating speed of the
terminal tractor.
5 6
6. Engine tachometer. This gauge indicates the engine revolu-
tions per minute.
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20 4 Instruments and controls
Dashboard panel
Gauges and switches
1. Voltmeter. This gauge indicates the status of the engine charg-
1 2 ing system in volts. If the engine is running, the gauge indicates
the alternator output voltage. If the engine is not running, the
gauge indicates the battery output voltage.
2. Heating and air conditioning controls. Details are described
on the following pages.
3. Hourmeter. This gauge indicates the engine operating hours.
4. Work light.
5. Option switches.
6. Ignition key lock.
7. Wiper control knob. This switch operates the windshield wash-
ers if equipped. The wipers have two speeds: low and high.
3 4 5 6 7
Side dashboard panel

Driving direction selector and brake control
1. Air pressure gauge. This gauge indicates the amount of air
1 2 pressure in the air tank in MPa.
2. Driving direction selector. Details are described on following
pages.
3. Trailer air supply valve. This valve controls the trailer air supply.
4. Parking brake control valve. This valve controls the air supply
to the parking brakes on both the tractor and the trailer.
3 4
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Fifth wheel control

This control operates fifth wheel.
Backward: The fifth wheel is backward raised.
Forward The fifth wheel is lowered.
Fifth wheel unlatch button

This button when pushed releases the fifth wheel jaws.
Indicator lights
Symbol Explanation
Park Wait to start
P
P
Left turn Water in fuel
High beam Heater air intake
Right turn Low battery
Low air Low fuel level
Check engine Low oil pressure

!
Stop engine High engine water temp
Check transmission Low engine water level

!
Service engine soon High trans oil temp
Operator's manual
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22 4 Instruments and controls - 4.3 Ignition
4.3 Ignition
General
Prior to starting the engine, turn the power to the ignition key lock
on with the main switch.
Main switch
The switch is located at left side of the footsteps (A).
The main switch is used to turn the power supply from the batteries
to the tractor electric devices on or off.
Power on Power from the batteries to the electric devices is on.

Power off Power from the batteries to the electric devices is off.
A
Main switch
Ignition key lock

The switch (1) is located on the instrument panel.
Position Off Circuits are turned off and engine is shut down.
The ignition key can be removed from the lock in this
position only.
Position Tractor's electrical accessory circuit is activated.
Accessory
Position Starter motor is engaged and after "wait to start" light is
Run turned off, the engine may be started.
Position Starting position.
Start
Starting the engine

Terminal tractors are designed to start in N (neutral) only. The
starter should not operate if the vehicle is in any other gear.
1 Prior to starting the engine, set the parking brake.
2 Place the transmission control in neutral.
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4 Instruments and controls - 4.3 Ignition 23
3 Apply the service brakes using the floor mounted treadle valve
and hold the brakes in the position.
4 Insert the ignition key into the switch and rotate the key clockwise
to the Run position.
5 Wait for the “wait to Start” light on the dash to go out if the vehicle
is equipped with one.
6 Turn the key to the start position. when engine starts, release the
key and allow the switch to remain in the Run position.
NOTE
Do not run a cold engine at high speed!
Stopping the engine

Engage the parking brake. Diesel engines generate large amounts of
heat. Internal engine parts on any diesel engine need to cool down
before the engine is shut off.
The operator should allow the engine to idle for at least 3 minutes prior
to shutting the engine down. This cool down period allows the coolant
to dissipate internal engine heat. Stop the engine by turning the igni-
tion key to position Off.
Shutting a hot engine down without a cool down period may cause an
immediate and excessive increase in engine temperature. This could
severely damage internal engine components.
NOTE
Allison transmissions are unlike an automobile transmission in one
important regard. They do not have a park position.
CAUTION
Always apply the parking brake. Never park the vehicle
by leaving it in gear. Always place the transmission
shifter selector in the "neutral" position.
Never park a tractor trailer combination unless the
trailer parking brakes are operational and applied.
If the engine does not start within 30 seconds, release
the starter switch and wait 3 minutes to allow the starter
motor to cool.
If after 3 repeated attempts, the engine still fails to start,
stop and determine the cause. The starter motor may
be damaged by repeated attempts to start the engine.
Operator's manual
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24 4 Instruments and controls - 4.5 Gear and multi-function lever
4.5 Gear and multi-function lever
General
The driver selects the driving direction of the tractor with the driving
direction selector.
About selecting driving direction and gear

The terminal tractor has four speeds forforward and one for reverse.
Do not move off if the gauge readings are not normal or any of the
warning symbols is lit.
Select the desired driving direction with the driving direction selector
( A). D is for driving forward and R is for reverse and N is for neutral,
respectively.
The current gear is indicated in the gear selector display.
Gearbox is automatic but you can select lower gear manually with
arrow switches.
A The tractor moves off by increasing the engine speed. Move off with
a gear corresponding to the load; the heavier the load, the lower the
gear. Gears can be shifted up and down with arrows also when the
tractor is moving.
Driving direction selector

The switch is located on the side dashboard panel. Use buttons to
1. Driving direction - Reverse
4 2. Driving direction - Neutral

3. Driving direction - Drive
4. Digital display
5. Mode button - display Mode/Diagnostic button
1 R MODE 5 6. Up arrow - Press the up arrow when D to request the next higher
range. Continuously pressing the up arrow will request the high-
est range available.
2 N 6 7. Down arrow - Press the down arrow when D to request the next
lower range. Continuously pressing the down arrow will request
the lowest range available.
3 D 7
NOTE
Allison transmissions are unlike an automobile transmission in one
important regard. They do not have a park position.
4.5.1 Oil level and diagnostic

Checking fluid levels
Use following procedure to display oil level information if the trans-
mission is equipped with the option.
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4 Instruments and controls - 4.5.1 Oil level and diagnostic 25
1 Park the vehicle on a level surface, shift to N and apply the parking
brake.
2 Press the UP and DOWN arrow buttons simultaneously.
3 The fluid level reading may be delayed until the following condi-
tions are met:
- the engine is at idle (below 1000 rpm)
- The fluid temperature is between 60°C and 104°C
- Transmission is in Neutral
- The vehicle has been stationary for approximately two mi-
nutes to allow the fluid to settle.
The indication of delayed fluid level check for pushbutton and

lever selectors with double flashing display and numerical cound-
down in the digital display.
4 The shift selector displays the oil level as follows:
Reading Explanation
oL oK Oil level is appropriate
Oil level is 1 quart below the full transmission
OL, LO, 01
level
Oil level is 1 quart above the full transmission
OL, HI, 01
level
If there is a measuring fault, measuring is interrupted and the display

shows error codes according to the following table:
Code Explanation
oL0X Setting time is too short.
oL50 Engine speed is too low
oL59 Engine speed is too high
oL65 The gear is not in neutral
oL70 Oil temperature is too low
oL79 Oil temperature is too high
oL89 Shaft movement detected
oL95 Fault in oil level sensor
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26 4 Instruments and controls - 4.5.2 Diagnostics
5 Press any range button to exit oil level display mode.
D
Range selector
NOTE
If fluid level is too high, the fluid can aerate, causing the
transmission to shift erratically or overheat.
The oil level sensor compensates for fluid temperature.
CAUTION
Incorrect fluid level can damage the transmission.
4.5.2 Diagnostics
General
If there aren't any active faults, the display shows two lines. When
a fault is active, the display shows the code in three sections.
Diagnostic procedure
1 Park the vehicle on a level surface, shift to N and apply the
parking brake.
2 Press the UP and DOWN arrow buttons simultaneously twice.

An example of an error code “D1, 25, 11“
“D1” shows the location of the fault between D1 and D5. Errors can
be browsed with the mode button. Sections of the error codes blink
on the screen until the next error is selected with the mode button.
The second section of the code shows the main code “25“
The last numbers show the subcode “11“
The error log is cleared by keeping the mode button pressed down
for 10 seconds. Exit by pressing the mode button or by pressing the
gear selector in any direction.
3 Press any range button to exit oil level display mode.
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4 Instruments and controls - 4.5.2 Diagnostics 27
NOTE
If the gear selector is used in the oil level measuring mode or
diagnostic mode, the transmission immeadiately returns to normal
mode.
Transmission error code lists are included in the last pages of this
manual.
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28 4 Instruments and controls - 4.6 Control lever
4.6 Control lever
Fifth wheel control

The control lever is located on the side dashboard panel.
Backward The fifth wheel is raised.

Forward The fifth wheel is lowered.
NOTE
When lowering the fifth wheel, ensure that there are no
obstructions!
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4 Instruments and controls - 4.7 Pedals 29
4.7 Pedals
General
The accelerator and brake pedals are on the floor in front of seat for
RHD. For LHD the accelerator pedal is on the firewall.
Brake pedal, item 1, and accelerator pedal, item 2, in the figure.
Accelerator pedals
The tractor is equipped with mechanical accelerator pedals.
Brake pedals
The brake pedals are of the pneumatic type and they are used to con-
trol the drum brakes at the steering and drive axles.
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30 4 Instruments and controls - 4.9 Operator's seat
4.9 Operator's seat
About the seat

Each driver can quickly find the correct position with the seat height,
back rest tilt and seat cushion tilt adjustments.
ALWAYS keep the seat belt fastened during operation.
Seat adjustments
Item 1 Back angle adjustment.

Item 2 Seat position adjustment.
Item 3 Height adjustment.
1
To raise seat, push lever upwards. To lower seat, push
lever downwards.
NOTE
Adjusted seat position should aide drivers visibility and vehicle
control.
Operator's manual
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4 Instruments and controls - 4.10 Heating / Air conditioning 31
4.10 Heating / Air conditioning
General
This chapter describes the operation of the following systems and
their controls.
• Cab heating system
• Cab air conditioning system
Cab heating system

The cab heating system is connected to the engine cooling system.
When the engine is at the normal operating temperature, the temper-
ature of the air supplied by the heater to the cab can be adjusted. The
speed of the air flow can be adjusted by changing the heater fan speed
from the front panel.
The heater draws air through the air filter at the cab front wall and
blows the air evenly to the cab through the air vents.
Adjusting the heating and air conditioning

These five switches regulate the temperature and air volume of the
1 2 3 4 cabin. Switch 2, 3, 4 and 5 only have two positions: On and Off.
Heater adjustments
1 Air volume switch
2 Evaporator switch
3 Blowers switch
4 Water valve switch
5 A/C switch
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32 4 Instruments and controls - 4.10 Heating / Air conditioning
Air volume
Air volume is operated with switch 1. This switch controls the fan
A B C D speed. It has four positions from left to right: close (A), low (B), me-
dium (C) and high (D).
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5 Handling 33
5 Handling
General
Use the terminal tractor according to the instructions in this manual
and STUDY THE INSTRUCTIONS CAREFULLY so that the safety
and reliability of the machine will be maintained.
The driver must also be very familiar with the working area and driving
conditions to prevent safety hazards to the people or equipment on
the site.
In addition to the instructions in this manual, observe any local driving
and work instructions.
Safety
Leaving the cab in an emergency
Should an emergency occur, the driver can leave the cab quickly from
the side or rear door.
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34 5 Handling - 5.1 Running-in
5.1 Running-in
General
To ensure durability of the engine and transmission, it is important
that the engine is not operated under high load and at high speed
for extended periods of time during the first 300 hours of operation.
The engine and transmission temperature and oil pressure
gauges must be observed during operation and the engine must
be shut down IMMEDIATELY if the readings deviate from the nor-
mal values.
However, the engine may not be loaded at a too low a speed or
the engine allowed to run at idle for extended periods of time.
During the run-in period, the oils should be changed and filters be
replaced at shorter intervals than normally, before the scheduled
operation hours are reached.
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5 Handling - 5.2 Daily inspections 35
5.2 Daily inspections
General
Daily inspections performed by the driver are important to ensure the
safe and efficient operation of the machine.
It is recommended that the driver or the person responsible for main-
tenance of the machine carry out the inspections before each shift.
This way it can be ensured that the work does not commence with a
defective machine whose possible malfunctions are not repaired.
Instructions for the daily inspections can be found in section 6 of this
manual.
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36 5 Handling - 5.3 Handling error codes
5.3 Handling error codes
General
An illuminated warning light and an buzzer indicate malfunctions
in the tractor's components or systems. For warning symbols, refer
to Chapter 4.
If a warning light comes on and/or the buzzer is activated during
operation, locate and correct the malfunction causing the alarm
before you continue to work.
5.3.1 Warning symbols

General
The warning symbols provide the driver with information about any
device and system faults in the machine.
If any of the warning symbols on the instrument panel come on
during operation, the engine must, in most cases, be stopped IM-
MEDIATELY and the cause of the problem determined.
The warning lights and their operation are described in more detail
in Chapter 4.
Operator's manual
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5 Handling - 5.4 Operating 37
5.4 Operating
About safety
DANGER
Keep the seat belt fastened during operation.
Be careful when entering and leaving the machine.
WARNING
During operation, loaded Fifth wheel must be lifted at
least 50 mm from the lowest position. This way fifth
wheel is suspended by the lifting cylinders. Direct load
to the mechanical limiters during operation may cause
severe fractures to the lift boom.
WARNING
While operating the tractor, the coupled trailer usually
limits visibility from the cab to the driving surface.
During operation, ensure and pay attention to the
following issues:
• Before moving, make sure that there are no people
in the machine's way.
• Adjust your driving speed according to the visibility,
coupled load, and condition of the driving surface.
• Switch the work lights on if lighting conditions
require it. Sufficient lighting is a prerequisite for safe
traffic at the working area.
• Beware of areas near the edges of routes where the
edge may collapse and the machine can tip over or
fall.
• Pay attention to the total weight of the machine and
load. Do not drive on surfaces with insufficient load
capacity.
• Never go near a loaded terminal tractor if the fifth
wheel is up. Always turn the main switch off for
servicing or repairing the lift boom or fifth wheel.
• Pay attention to the overhead clearance signs. Be
aware of the total height of your vehicle combination
before you drive in places with restricted height.
• Be particularly careful when working in the vicinity
of power lines, piers, ramps, doors and gateways.
Operator's manual
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38 5 Handling - 5.4.1 Starting the engine
5.4.1 Starting the engine

General
Prior to starting the engine, turn the power to the ignition key lock
on with the main switch.
Main switch (A)

The switch is located at left side of the footsteps.
The main switch is used to turn the power supply from the batteries
to the tractor electric devices on or off.
A
Main switch
Ignition key lock

The switch (1) is located on the instrument panel.
Position Off Circuits are turned off and engine is shut down.
The ignition key can be removed from the lock in this
position only.
Position Tractor's electrical accessory circuit is activated.
Accessory
Position Starter motor is engaged and after "wait to start" light is
Run turned off, the engine may be started.
Position Starting position.
Start
Starting the engine

Prior to starting the engine, set the driving direction selector in the
neutral position.
Ensure that the parking brake is engaged.
Ensure that the emergency stop switch is in the upper position and
that the cable of the optional block heater has been disconnected.
Turn the ignition key to position Accessory. Turn the ignition key
clockwise until engine starts.
Release the key IMMEDIATELY once the engine has started and
set the engine speed to about 1000 rpm with the accelerator pedal.
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5 Handling - 5.4.1 Starting the engine 39
If the engine does not start within 15 seconds, wait for 30 seconds
before the next start attempt. Perform a new start attempt as descri-
bed above.
CAUTION
Never use starting fluids if you have problems starting
the engine. The engine could be damaged.
Do not run a cold engine at high speed!
NOTE
Do not run the engine over 1000 rpm for the first 30 sec. after each
start. Meaning of this limitation is to protect engine. Also the
machine pressures will fill up. Do not run a cold engine at high
speed!
If the engine is fitted with an engine block heater to ensure starting in

cold conditions, use the heater according to the heater manufacturer's
instructions. Remove the heater cable prior to starting the engine.
Starting with auxiliary batteries

If the charge level of the batteries has decreased or the batteries are
drained, the tractor engine can be started using 24-volt auxiliary bat-
teries according to the following instructions:
1. If the auxiliary batteries are on another vehicle, ensure that the
vehicles are not touching each other.
2. Connect one end of the positive (+) jump-start cable to the positive
terminal of the auxiliary battery (marked with red color, the letter
'P', or a plus sign). Ensure that the clamps are securely connected
to prevent sparking.
3. Connect the other end of the positive (+) jump-start cable to the
positive terminal of the drained battery (the cable to the starter
motor is connected to this terminal).
4. Connect one end of the negative (-) jump-start cable to the neg-
ative terminal of the auxiliary battery (marked with blue color, the
letter 'N', or a minus sign) and connect the other end of the cable
securely to, for example, the negative engine cable of the vehicle
with the drained battery.
5. Start the engine. Ensure that the cables do not touch each oth-
er while starting.
6. While starting, do not cut off the circuit going through the batteries
installed on the tractor.
7. Disconnect the jump-start cables in reverse order of connection.
DANGER
If electrolyte is spilled on the eyes or skin, flush the area
immediately with large quantities of water and consult
a doctor.
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40 5 Handling - 5.4.2 Selecting driving direction and gear
5.4.2 Selecting driving direction and gear

About selecting driving direction and gear
The terminal tractor has four speeds for forward and one for reverse.
Do not move off if the gauge readings are not normal or any of the
warning symbols is lit.
Select the desired driving direction with the driving direction selector
( A). D is for driving forward and R is for reverse and N is for neutral,
respectively.
The current gear is indicated in the gear selector display.
Gearbox is automatic but you can select lower gear manually with
arrow switches.
A The tractor moves off by increasing the engine speed. Move off with
a gear corresponding to the load; the heavier the load, the lower the
gear. Gears can be shifted up and down with arrows also when the
tractor is moving.
5.4.3 Steering
General
The tractor is equipped with hydrostatic steering where the front
wheels and the steering wheel are not mechanically connected
with each other.
The movements of the steering wheel are conveyed to the front
axle wheels hydraulically.
DANGER
Never let the tractor roll downhill if the engine is not
running.
When the engine is not running, the hydraulic pump
does not supply pressure to the steering system and
steering is very slow and limited.
5.4.4 Brakes
General
The pneumatic brake system is controlled with the brake pedal. If
a trailer is coupled to the tractor, the trailer brakes are also con-
trolled with the brake pedal if the pneumatic connections are con-
nected between the tractor and trailer.
The brake system is split into front and rear axle circuits. With the
dual circuit brake system, one circuit remains functional even if the
other circuit fails due to, for example an air leak.
Brake firmly but smoothly to reduce tyre and brake wear. Decrease
the brake pedal pressure slightly prior to stopping to stop the trac-
tor and trailer (if coupled) in a controlled manner.
Operator's manual
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5 Handling - 5.4.5 Parking brake 41
5.4.5 Parking brake

General
Engage the parking brake with the pull up knob. Pull up to apply the
brake and push down to release.
NOTE
Prior to getting up from the driver's seat, ensure that the parking
brake is engaged.
The parking brake is not to be used as a service brake, since
1 engaging the parking brake while the tractor is moving subjects
the transmission and brake system components to heavy loads!
5.4.6 Stopping the engine / parking

Stopping the engine
Put the gear to neutral by pressing the N button on the gear selector.
Engage the parking brake with the pull up knob. Let the engine to run
on idle for three minutes to let the temperature to stabilise. Stop the
engine by turning the ignition key to position 0.
Turn the main switch to the off position when leaving the machine.
NOTE
Never turn the main switch to the off position while the engine is
running, since the alternator is quickly damaged if the circuit is cut
off.
Operator's manual
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42 5 Handling - 5.5 Load handling
5.5 Load handling
General
In this context, load handling means transporting various trailers
with the tractor.
The maximum load for the Land H3510 fifth wheel is 25,000 kg,
respectively. The lifting height and minimum fifth wheel height from
the driving surface are determined by the tractor equipment and
hence vehicle-specific.
The load handling instructions presented in this section are gen-
eral guidelines only and not intended for work instructions as such.
The tractor may be operated only by a trained driver. Local con-
ditions and loads can cause exceptions to these instructions.
WARNING
When transporting a trailer along a steep ramp, always
drive “under” the trailer.
I.e. push behind the trailer when going upwards and
pull in front of the trailer when going downwards.
Otherwise the front end of the tractor may rise off the
surface causing loss of control of the machine.
During operation, loaded Fifth wheel must be lifted at
least 50mm from the lowest position. This way fifth
wheel is suspended by the lifting cylinders.Direct load
to the mechanical limiters during operation may cause
severe fractures to the lift boom.
5.5.1 Transporting a trailer

General
Keeping the driving surface clean is essential for the safety and
durability of the tractor.
When driving, select the driving speed so that any driving surface
irregularities or inclination do not pose a safety hazard and the
tractor structure is not unnecessarily stressed.
When moving off and stopping, accelerate and brake smoothly.
Transporting a trailer
Back the tractor under the trailer to be transported so that the fifth
wheel is coupled to the kingpin of the trailer or the trailer horse is
attached to the trailer.
Connect the tractor brake hoses to the trailer brake fittings and run
the engine at 1500 rpm until the brake system pressure reaches the
normal level and the trailer brakes are released.
Lift the trailer so that, if necessary, its support legs can be cranked to
the fully retracted position, or hinged support legs can be turned and
secured parallel to the trailer bed. While lifting the trailer, be careful
not to damage any other vehicles possibly parked in the vicinity.
Transport the trailer into confined spaces by pushing.
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5 Handling - 5.5.1 Transporting a trailer 43
When driving to a loading ramp, use gear that is low enough.

When the trailer is in the correct position, lower the trailer onto its
support legs or trailer horse and disconnect the brake hoses. Release
the kingpin from the fifth wheel by pushing the kingpin release switch
until the red kingpin lock indicator light on the instrument panel is lit.
Keep the switch depressed while the indicator light is lit and pull the
tractor clear of the parked trailer.
Release the switch when the tractor is clear of the trailer; indicator
light remains lit to indicate that the kingpin is open.
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44 5 Handling - 5.5.1 Transporting a trailer
Operator's manual
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6 Inspection and maintenance 45
6 Inspection and
maintenance
General
This chapter describes the following issues regarding inspection and
maintenance:
• Daily inspections
The Daily inspections section specifies the inspection procedures
which the driver or the person responsible for maintenance of the
machine carry out before each shift.
• Maintenance
The Maintenance section contains instructions on performing the
daily inspections and associated maintenance procedures.
• Service
This section includes procedures concerning scheduled mainte-
nance.
DANGER
The engine must always be stopped for maintenance
and inspection.
Only a person who has been familiarised with the
machine's controls and devices may be in the cab
during inspection and maintenance.
DANGER
Fuel is highly flammable.
Do not smoke or use an open flame when refueling and
servicing the fuel system.
CAUTION
Avoid skin contact with oils and lubricants. Use
protective gloves during maintenance.
Operator's manual
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46 6 Inspection and maintenance - 6.1 Daily inspection
6.1 Daily inspection
General
Daily inspections and any required maintenance carried out by a
professional and trained person ensure that the operational safety
and reliability of the machine will be maintained.
It is recommended that the driver or the person responsible for
maintenance of the machine carry out the inspections before each
shift. This way it can be ensured that the work does not commence
with a defective machine.
DANGER
If an issue requiring service or repair is detected in the
daily inspection, do not start working with the machine
until the service or repair has been carried out.
Inspection table
Item Inspection method Note
General
Any oil, fluid, or air leaks Visually / by listening
and visible damage
1 Engine
Oil level Dipstick Add the recommended oil if necessary.
Coolant level in the ex- Indicator light is lit in the panel when the cool- Tilt the cab to the service position and add the rec-
pansion tank ant level is too low. ommended coolant, if necessary.
The level can be visually checked through the
plastic expansion tank.
Fuel level from the fuel Visually Fill the tank with high-quality diesel before each work
gauge shift.
4 Brakes
Operation of brakes Brake test immediately after moving. Also test the operation of the parking brake!
5 Steering
Operation of steering Make sure steering effort is smooth and light.
6 Suspension and wheels
Wheel attachment Visually Pay special attention to the wheels since they are only
attached to the axle by the friction force between the
rim seating surface and mounting nuts.
Tyre pressure and con- Visually Moreover, pay attention to any surface damage (for
dition example, deep cuts in the tire surface).
7 Load handling
Operation of the fifth Visually Lubricate the fifth wheel surface and kingpin locking
wheel and lift boom components with the recommended grease if neces-
sary.
9 Frame, cab, and accessories
Operator's manual
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6 Inspection and maintenance - 6.1 Daily inspection 47
Item Inspection method Note

Controls, instruments, Visually Check operation before and after starting the engine.
mirrors and indicator
lights
Cab hold down latch Visually Working is prohibited unless the latch is locked prop-
erly.
Operation of beacons Visually / by listening
and buzzers
Windscreen washer Visually / by testing Fill the washer fluid reservoir with recommended
washer fluid before each work shift.
10 Common hydraulics
Oil level in the tank Sight glass If necessary, add the recommended oil to the tank
through the quick coupling in the return filter.
12 Common pneumatics
Drain moisture from the Pull the drain plug cord from the air pressure
air pressure tanks tanks.
Operator's manual
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48 6 Inspection and maintenance - 6.2 Maintenance
6.2 Maintenance
General
This section contains instructions on performing the daily inspec-
tion and maintenance procedures specified in the inspection table.
IMPORTANT
To maintain machine warranty, use only the oils,
greases, and fluids specified in Chapter 9, as well as
original filters and other service parts available from
our spare parts department.
By using the lubricants and fluids specified in this
manual and original filters and other service parts it can
be ensured that the safety and reliability of the machine
will be maintained.
Safety
• Always stop the engine prior to performing maintenance pro-
cedures unless they require the engine to be running.
• Maintenance may only be performed by trained and pro-
fessional persons to ensure that the safety and reliability of
the machine will be maintained at the intended level.
• Do not service the machineunless you are absolutely sure
about the instructions and regulations on performing the pro-
cedures safelyIf necessary, ask your work instructor or our
maintenance department for guidanceon the issues regard-
ing safety in maintenance.
• Do not dispose of the waste oil, grease, and fluids in the drain
or on the ground. Clean any fluid leaks from the machine and
ground.
• Take responsibility for the environment!
NOTE
If you wash the machine with a pressure washer, do not direct the
water jet directly towards the radiator, electric devices, bearings,
and shaft seals since they can be damaged!
Operator's manual
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6 Inspection and maintenance - 6.2 Maintenance 49
Tilting the cab

The inspection table specifies the inspection procedures for which
the cab must be tilted to the maintenance position as shown in the
picture.
• Prior to tilting the cab to the maintenance position, ensurethat the
cab dooris properly closedand any loose items are removed
from the cab.
• Prior to lowering the cab, check that the cab path is free of ob-
structions.
• If the tilting hydraulics hoses or fittings are to be replaced, use
only original spare parts and accessories.
DANGER
prohibited!
Electric tilt pump control unit

The tractor is equipped with electric tilt pump control unit. The controls
are located next to the rear fender.
Cab hold-down hook is automatic and works hydraulically with priority
valve.
Turn on the main switch to operate the tilt pump.
To tilt the cab to the service position, pull the release cable and hold
the switch in the up position. After the cab has traveled about 40
centimeters, release the cable and continue tilting the cab. Make sure
the cab is fully tilted and the safety stop is engaged to the cylinder
before working under the cab.
To tilt the cab back to the operating position, pull first firmly from the
release cable to release the safety stop and then hold the switch in
the down position. Hold the switch in the down position for 5 seconds
after the cab is completely lowered to fully engage hold-down hook.
Operator's manual
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50 6 Inspection and maintenance - 6.2.1 Engine and transmission lubrication systems
6.2.1 Engine and transmission lubrication

systems
Checking the engine lubrication oil level
The dipstick is on the right side of the tractor, on top of the front
bumper behind the service hatch.
The engine oil level is correct when the level is between the MIN and
MAX marks on the dipstick.
Check the level when the engine has been stopped for at least a few
minutes.
Clean the dipstick before checking the oil level.
If necessary, tilt the cab and add the recommended oil from the oil fill
cap on top of the engine.
NOTE
If you have to add oil, be careful to keep the oil free of other fluids
or impurities. Impurities in oil damage the engine.
Checking the transmission lubrication oil

level
The transmission oil dipstick is located under the cab.
The transmission oil level is correct when the level is between the
MIN and MAX marks on the dipstick.
Check the level when the engine has been stopped for at least a few
minutes.
Clean the dipstick before checking the oil level.
If necessary, add the recommended oil from the dipstick tube.
NOTE
If you have to add oil, be careful to keep the oil free of other fluids
or impurities. Impurities in oil damage the transmission.
Operator's manual
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6 Inspection and maintenance - 6.2.2 Cooling system 51
6.2.2 Cooling system

Checking the coolant level
The cooling system expansion tank (1) is located at the right side of
the tractor for LHD and at the left side of the tractor for RHD, on top
of the front bumpers near the air filter.
When the engine is cold, the correct amount of coolant in the expan-
sion tank is about 30 % of the tank volume, and if the engine is at the
operating temperature, the amount is about 70 %. Check the level
from the transparent tank. You may see the level better with flashlight
or by tilting the cab.
If necessary, tilt the cab and add the recommended coolant to the
tank through the filler cap.
NOTE
If you have to add coolant to the tank, be careful to keep the fluid
free of any impurities. Impurities in coolant damage the coolant
pump and impair engine coolant circulation.
1 CAUTION
1. Transparent expansion tank
Allow the engine to cool down for a while and open the
cap carefully if you have to add coolant to the tank.
Steam or hot coolant may be discharged from the
expansion tank and cause burns.
6.2.3 Charging system for the batteries

Checking the alternator belt
Replace the belt if it is clearly worn, oily, or visibly cracked.
The belt tightness is correct if the deflection is 10...15 mm when the
belt is pressed with a finger in the centre of the free span.
A If necessary, tighten the belt by loosening the alternator mounting
screws and then turn the alternator in its brackets away from the en-
gine to achieve the tightness corresponding to the deflection speci-
fied above. Tighten the mounting screws when the adjustment is
done.
A. Alternator belt
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52 6 Inspection and maintenance - 6.2.4 Engine air filter
6.2.4 Engine air filter

The air filter
The air filter (1) is changed during scheduled maintenance. Depend-
1 ing on the operating conditions, the air filter may clog during a rela-
tively short operating period.
An indicator indicating the flow-through capacity of the air filter is op-
tional equipment.
Contact the person responsible for maintenance if the air vacuum
indicator indicates. Continue working only after the filter has been
replaced.
1. Air filter
6.2.5 Fuel system

Refueling
The fuel tank is located on the right side of the LHD tractor and left
side of the RHD tractor.
Check the fuel level from the fuel gauge in the cab while the machine
power is switched on.
Never allow the fuel tank to run completely empty since this allows
air to enter the fuel system and it becomes necessary to bleed the
system.
Refuel the tank with high-quality diesel fuel through the filler cap.
Leave the fuel level approximately 10% from the top.
DANGER
Fuel is highly flammable.
Do not smoke or use an open flame when refueling and
servicing the fuel system.
Operator's manual
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6 Inspection and maintenance - 6.2.6 Hydraulic system 53
6.2.6 Hydraulic system

Checking the hydraulic oil level in the hydraulic
oil tank
The hydraulic oil tank is located on the left side of the LHD tractor and
B right side of the RHD tractor.
The sight glass (A) indicating the oil level in the tank is at the side of
the tank. The oil level is correct when the level is at the "full cold" line.
Lower the lift boom down prior to checking the oil level.
If necessary, add the recommended hydraulic oil through the filler cap
(B).
A NOTE
If you have to add oil to the hydraulic oil tank, be careful to keep
the oil free of other fluids or impurities. Impurities damage the
hydraulic system.
A. Sight glass, B. Filler cap
Operator's manual
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54 6 Inspection and maintenance - 6.3 Service
6.3 Service
General
For the operational safety and reliability of the machine, it is ex-
tremely important that the inspections and maintenance proce-
dures are carried out according to the maintenance programme.
Inspections and maintenance carried out by a professional and
trained person ensure that the operational safety and reliability of
the machine will be maintained at the intended level.
It is recommended that servicing be performed by the mainte-
nance division of manufacturer or an authorized service outlet.
IMPORTANT
Following the maintenance programme is a
prerequisite for maintaining the machine warranty.
Operator's manual
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6 Inspection and maintenance - 6.3 Service 55
Scheduled maintenance
KALMAR TRUCK PREVENTION AND MAINTENANCE MANUAL
USE NON-SYNTHETIC LUBRICANT FOR ELECTRONIC MOTOR (EXCEPT QSB-155) RDS TRANSMISSION
TRUCK NUMBER LOCATION TECHNICIAN HOURS DATE
EACH OF THE FOLLOWING ITEMS SHOULD BE CHECKED AND THE CORRESPONDING BOX MARKED WITH THE APPROPRIATE NOTATION.
√ = SATISFACTORY 0 = ADJUSTMENT NECESSARY X = REPAIRS NEEDED
“A” INSPECTIONS SHOULD BE PERFORMED AT 250 HOUR INTERVA LS, “B” INSPECTIONS AT 500 HOUR INTERVA LS, “C” INSPECTIONS AT 1000 HOUR INTERVALS,
AND “D” INSPECTIONS AT 2000 HOUR INTERVALS.
OPERATION A B C D OPRATION A B C D
CAB – INTERIOR UNDER VEH ICLE
CHECK OPERATION OF NEUTRAL START CHECK STEERING GEAR
CHECK OPERATION OF ALL GAUGES CHECK BRAKE LININGS AND DRUMS
CHECK LOW AIR BUZZER AND LIGHT CHECK SPRINGS
CHECK WINDSHIELD WIPER OPERATION CHECK SHOCK ABSORBERS (IF APP.)
CHECK WINDSHIELD WASHER OPERATION (IF TORQUE FRONT AXLE MOUNTING BOLTS
CHECK ACCELERATOR FOR FREE OPERATION TORQUE KING PINS DRAW KEY NUT
CHECK HORN(S) OPERATION CHECK POWER STEERING PUMP
CHECK AIR SYSTEM FOR MAXIMUM 120 PSI CHECK HYDRAULIC PUMP
CHECK AIR SYSTEM FOR LEAK DOWN CHECK STARTER MOUNTING AND CONNECTIONS
CHECK OPERATION OF BACK UP ALARM CHECK ENGINE AND TRANSMISSION FOR LEAKS
CHECK OPERATION OF SHIFT LOCK OUT CHANGE ENGINE OIL AND FILTER
CHECK HVA C SYSTEM CHANGE TRANSMISSION EXTERNAL FILTER
BLOWER MOTOR OPERATION CHANGE TRANSMISSION FLUID
TEMPERATURE CONTROL CHECK ENGINE AND TRANSMISSION MOUNTS
AUXILIARY FAN(S) (IF APP.) CHECK WHEEL SEALS FOR LEAKS
A/C OPERATION (IF APP.) CLEAN REAR AXLE BREATHER
DEFROSTER OPERATION CHECK DIFFERENTIAL FOR LEAKS
CHECK OPERATION OF PTO CONTROL (IF APP.) CHECK DIFFERENTIAL OIL LEVEL
TH
CHECK 5 WHEEL UNLAT CH CONTROL CHANGE DIFFERENTIAL OIL
CHECK OPERATION OF BOOM CHECK LIFT CYLINDERS FOR LEAKS
CHECK FIRE EXTINGUISHER CHARGE (IF APP.) CHECK OTTO-RIDE RUBBER ISOLATOR (IF APP.)
CHECK SEAT BELT OPERATION TORQUE REAR AXLE MOUNTING BOLTS
CHECK SIDE DOOR LATCH OPERATION CHASSIS
CHECK REAR DOOR LATCH OPERATION CHECK FRONT AXLE OIL LEVEL (IF APP.)
CHECK DOME LIGHT OPERATION REPACK FRONT WHEEL BEARINGS (IF APP.)
CHECK ALL GLASS AND MIRRORS CHECK BATTERY CABELS & HOLDDOWNS
CHECK OPERATION OF WINDOWS CHECK BATTERY BOX COVER HOLDDOWNS
CAB DOWN – EXTERIOR CHECK BATTERIES FOR CRACKS OR ACID DAMAGE
CHECK CAB ACCESS STEPS AND HANDLES CLEAN BATTERY CABLE CONNECTIONS
CLEAN HEATER / AC FILTER (IF APP.) DRAIN WATER FROM AIR TANKS
CHECK REAR DOOR ROLLER / SLIDE ADJUSTMENT CHECK AND TORQUE ALL WHEEL NUTS
CHECK GLADHAND SEALS AND TRAILER AIR CHECK WHEELS
CHECK TRAILER LIGHT CORD CHECK TIRE AIR PRESSURE & TREAD DEPTH
CHECK HEADLIGHTS / MARKER LIGHTS CHECK REAR AXLE PLANETARY FLUID LEVEL (IF APP.)
CHECK TURN SIGNALS INSPECT CATWALK
CHECK STROBE LIGHT (IF APP.) CHECK FRAME FOR CRACKS
CHECK SPOTLIGHTS CHECK MUD FLAPS / FENDERS (IF APP.)
CHECK WIPER BLADES CHANGE HYDRAULIC SYSTEM FILTER
CHECK WINDSHIELD WASHER FLUID LEVEL CHECK HYDRAULIC FLUID LEVEL
CAB UP CHANGE HYDRAULIC FLUID
CHECK OPERATION OF CAB TILT PUMP CLEAN HYDRAULIC TANK VENT
CHECK CAB SAFETY PROP LUBRICATION
CHECK CAB SUSPENSION AND LATCH CHECK / LUBRICATE SIDE DOOR HINGES
CHECK INTAKE DUCTING FOR LEAKS CHECK / LUBRICATE REAR DOOR ROLLERS
CHECK RADIATOR FOR LEAKS CHECK / LUBRICATE CAB HINGE PINS
CHECK RADIATOR MOUNTS CHECK / LUBRICATE HOOD HINGES
CHECK COOLANT LEVEL AND CONCENTRATION CHECK / LUBRICATE STEERING SLIP JOINT
CHECK AND ADJUST COOLANT ADDITIVE (IF APP.) CHECK / LUBRICATE STEERING U-JOINTS
CHANGE ENGINE COOLANT CHECK / LUBRICATE KING PINS AND TIE ROD ENDS
CHECK COOLANT HOSES AND CLAMPS LUBRICATE TRACTION ROD
CHECK FAN CLUTCH FOR OPERATION (IF APP.) CHECK / LUBRICATE SLACK ADJUSTERS
CHECK ENGINE COOLING FAN FOR CRACKS CHECK / LUBRICATE SPRING PINS AND BUSHINGS
CHECK ENGINE BELT(S) AND TENSIONER CHECK / LUBRICATE DRIVELINE U-JOINTS
CHANGE ENGINE COOLANT FILTER (IF APP.) CHECK AND LUBE LOWER BOOM CYLINDER BEARING
CHECK ENGINE AND TRANSMISSION FOR LEAKS CHECK AND LUBE OTTO-RIDE PIVOT POINTS (IF APP.)
DRAIN FUEL WATER SEPARATOR ADD GREASE TO AUTOLUBE SYSTEM (IF APP.)
TH
CHANGE FUEL FILTER / FUEL WATER SEPARATOR CLEAN, CHECK, ADJUST AND LUBE 5 WHEEL JAWS
TH
CHECK AIR RESTRICTION GAUGE (IF APP.) CHECK AND LUBRICATE 5 WHEEL TOP PLATE
TH
CHANGE AIR FILTER AS NEEDED CHECK AND LUBRICATE 5 WHEEL PIVOT PINS
CHANGE AIR DRYER DESICCANT (IF APP.) AS NEEDED CHECK AND LUBRICATE BOOM PIVOT BEARINGS
CHECK EXHAUST SYSTEM CHECK AND LUBE UPPER BOOM CYLINDER BEARING
CHECK TRANSMISSION FLUID LEVEL CHECK / LUBRICATE HYDRAULIC OIL PUMP DRIVE
CLEAN TRANSMISSION BREATHER TEST DRIVE
TORQUE CAB TO DECK MOUNTING BOLTS DRIVE VEHICLE TO CHECK FOR OVERALL OPERAT ION
Operator's manual
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KALMAR TRUCK PREVENTION AND MAINTENANCE MANUAL

USE NON-SYNTHETIC LUBRICANT FOR SB-155-RDS TRANSMISSION
“A” INSPECTIONS SHOULD BE PERFORMED AT 250 HOUR INTERVA LS, “B” INSPECTIONS AT 500 HOUR INTERVA LS, “C” INSPECTIONS AT 1000 HOUR INTERVALS,
AND “D” INSPECTIONS AT 2000 HOUR INTERVALS.
TH
CHECK 5 WHEEL UNLATCH CONTROL
CHECK OPERATION OF BOOM CHANGE DIFFERENTIAL OIL
CHECK LIFT CYLINDERS FOR LEAKS
CHECK CAB SAFETY PROP LUBRICATIO N
CHANGE ENGINE COOLANT CHECK / LUBRICATE SHOCK ABSORBER
CHECK COOLANT HOSES AND CLAMPS CHECK / LUBRICATE KING PINS AND TIE ROD ENDS
CHECK FAN CLUTCH FOR OPERATION (IF APP.) CHECK / LUBRICATE TRACTION ROD
CHECK ENGINE COOLING FAN FOR CRACKS CHECK / LUBRICATE SLACK ADJUSTERS
CHECK ENGINE BELT(S) AND TENSIONER CHECK / LUBRICATE SPRING PINS AND BUSHINGS
CHANGE ENGINE COOLANT FILTER (IF APP.) CHECK / LUBRICATE DRIVELINE U-JOINTS
CHECK ENGINE AND TRANSMISSION FOR LEAKS CHECK AND LUBE LOWER BOOM CYLINDER BEARING
DRAIN FUEL WATER SEPARATOR CHECK AND LUBE OTTO-RIDE PIVOT POINTS (IF APP.)
CHANGE FUEL FILTER / FUEL WATER SEPARATOR ADD GREASE TO AUTOLUBE SYSTEM (IF APP.)
TH
CHECK AIR RESTRICTION GAUGE (IF APP.) CLEAN, CHECK, ADJUST AND LUBE 5 WHEEL JAWS
TH
CHANGE AIR FILTER AS NEEDED CHECK AND LUBRICATE 5 WHEEL TOP PLATE
TH
CHANGE AIR DRYER DESICCANT (IF APP.) AS NEEDED CHECK AND LUBRICATE 5 WHEEL PIVOT PINS
CHECK EXHAUST SYSTEM CHECK AND LUBRICATE BOOM PIVOT BEARINGS
CHECK TRANSMISSION FLUID LEVEL CHECK AND LUBE UPPER BOOM CYLINDER BEARING
CLEAN TRANSMISSION BREATHER CHECK / LUBRICATE HYDRAULIC OIL PUMP DRIVE
TORQUE CAB TO DECK MOUNTING BOLTS TEST DRIVE
DRIVE VEHICLE TO CHECK FOR OVERALL OPERAT ION
Operator's manual
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KALMAR TRUCK MAINTENANCE SHEET

USE “TRANSYND” LUBRICANT AND ALLISON FILTER FOR ELECTRONIC MOTOR (EXCEPT QSB-155) -RDS TRANSMISSION
“A” INSPECTIONS SHOULD BE PERFORMED AT 250 HOUR INTERVA LS, “B” INSPECTIONS AT 500 HOUR INTERVA LS, “C” INSPECTIONS AT 1000 HOUR
INTERVALS, AND “D” INSPECTIONS AT 2000 HOUR INTERVA LS.
CHECK ACCELERATOR FOR FREE OPERATION CHECK KING PINS DRAW KEY NUTS
CHECK 5TH WHEEL UNLATCH CONTROL CHANGE DIFFERENTIAL OIL
CHANGE ENGINE COOLANT CHECK / LUBRICATE KING PINS AND TIE ROD ENDS
CHECK COOLANT HOSES AND CLAMPS LUBRICATE TRACTION ROD
CHECK FAN CLUTCH FOR OPERATION (IF APP.) CHECK / LUBRICATE SLACK ADJUSTERS
CHECK ENGINE COOLING FAN FOR CRACKS CHECK / LUBRICATE SPRING PINS AND BUSHINGS
CHECK ENGINE BELT(S) AND TENSIONER CHECK / LUBRICATE DRIVELINE U-JOINTS
CHANGE ENGINE COOLANT FILTER (IF APP.) CHECK AND LUBE LOWER BOOM CYLINDER BEARING
CHECK ENGINE AND TRANSMISSION FOR LEAKS CHECK AND LUBE OTTO-RIDE PIVOT POINTS (IF APP.)
DRAIN FUEL WATER SEPARATOR ADD GREASE TO AUTOLUBE SYSTEM (IF APP.)
TH
CHANGE FUEL FILTER / FUEL WATER SEPARATOR CLEAN, CHECK, ADJUST AND LUBE 5 WHEEL JAW S
TH
CHECK AIR RESTRICTION GAUGE (IF APP.) CHECK AND LUBRICATE 5 WHEEL TOP PLATE
TH
CHANGE AIR FILTER AS NEEDED CHECK AND LUBRICATE 5 WHEEL PIVOT PINS
CHANGE AIR DRYER DESICCANT (IF APP.) AS NEEDED CHECK AND LUBRICATE BOOM PIVOT BEARINGS
CHECK EXHAUST SYSTEM CHECK AND LUBE UPPER BOOM CYLINDER BEARING
CHECK TRANSMISSION FLUID LEVEL CHECK AND LUBE UPPER HYDRAULIC PUMP DRIVE
CLEAN TRANSMISSION BREATHER TEST DRIVE
TORQUE CAB TO DECK MOUNTING BOLTS DRIVE VEHICLE TO CHECK FOR OVERALL OPERATION
Operator's manual
1328 0 eng 2012-05-15
KALMAR TRUCK PREVENTION AND MAINTENANCE SHEET

USE “TRANSYND” LUBRICANT AND ALLISON FILTER CLEANER FOR SB-155-RDS TRANSMISSION
“A” INSPECTIONS SHOULD BE PERFORMED AT 250 HOUR INTERVA LS, “B” INSPECTIONS AT 500 HOUR INTERVA LS, “C” INSPECTIONS AT 1000 HOUR
INTERVALS, AND “D” INSPECTIONS AT 2000 HOUR INTERVA LS.
TH
CHECK 5 WHEEL UNLATCH CONTROL CHANGE DIFFERENTIAL OIL
CHECK SPOTLIGHTS CHECK MUD FLAPS / FENDERS (IF APP. )
CHECK OPERATION OF CAB TILT PUMP CLEANs HYDRAULIC TANK VENT
CHANGE ENGINE COOLANT LUBRICATE SHOCK ABSORBER
CHECK COOLANT HOSES AND CLAMPS CHECK / LUBRICATE KING PINS AND TIE ROD ENDS
CHECK FAN CLUTCH FOR OPERATION (IF APP.) CHECK / LUBRICATE TRACTION ROD
CHECK ENGINE COOLING FAN FOR CRACKS CHECK / LUBRICATE SLACK ADJUSTERS
CHECK ENGINE BELT(S) AND TENSIONER CHECK / LUBRICATE SPRING PINS AND BUSHINGS
CHANGE ENGINE COOLANT FILTER (IF APP.) CHECK / LUBRICATE DRIVELINE U-JOINTS
CHECK ENGINE AND TRANSMISSION FOR LEAKS CHECK AND LUBE LOWER BOOM CYLINDER BEARING
DRAIN FUEL WATER SEPARATOR CHECK AND LUBE OTTO-RIDE PIVOT POINTS (IF APP.)
CHANGE FUEL FILTER / FUEL WATER SEPARATOR ADD GREASE TO AUTOLUBE SYSTEM (IF APP.)
TH
CHECK AIR RESTRICTION GAUGE (IF APP.) CLEAN, CHECK, ADJUST AND LUBE 5 WHEEL JAW S
TH
CHANGE AIR FILTER AS NEEDED CHECK AND LUBRICATE 5 WHEEL TOP PLATE
TH
CHANGE AIR DRYER DESICCANT (IF APP.) AS NEEDED CHECK AND LUBRICATE 5 WHEEL PIVOT PINS
CHECK EXHAUST SYSTEM CHECK AND LUBRICATE BOOM PIVOT BEARINGS
CHECK TRANSMISSION FLUID LEVEL CHECK AND LUBE UPPER BOOM CYLINDER BEARING
CLEAN TRANSMISSION BREATHER CHECK / LUBRICATE HYDRAULIC OIL PUMP DRIVE
UNIT
TORQUE CAB TO DECK MOUNTING BOLTS TEST DRIVE
DRIVE VEHICLE TO CHECK FOR OVERALL OPERATION
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Lubrication
5
6
3
10
7
1
15 2
14 13 12
11
Number Maintenance item

1 Lubricating the throttle linkage
2 Lubricating the universal shaft joints
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3 Lubricating the front axle kingpins

4 Lubricating the driveline slip yoke
5 Lubricating the drag link pivots
6 Lubricating the slack adjusters brake cam pivot
7 Lubricating the tie rod joints
8 Lubricating the steering slip joint
9 Lubricating the front spring shackles
10 Lubricating the front wheel bearings
11 Lubricating the lifting frame bearing
12 Fifth wheel: grease nipples, jaws slide
13 Lubricating the fifth wheel joints
14 Lubricating the lifting cylinder ends
15 Lubricating the cab tilt latch
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7 Transport of machine 61
7 Transport of machine
7.1 Towing
General
Starting the tractor by towing or pushing is not possible.
If the engine cannot run while towing, the towed tractor must be at-
tached to the towing tractor with a tow bar.
The brakes operate normally as long as the pneumatic system pres-
sure remains over 5 bar. The parking brake is engaged gradually by
the springs in the brake cylinder while the system pressure drops from
5 bar to 0 bar. If the tractor is towed when the brake system pressure
is below 5 bar, the parking brake must be released mechanically (for
detailed instructions, see section 7.1.1 "Releasing the parking brake
mechanically").
The propeller shafts between the transmission and axles of the towed
tractor must be removed at the appropriate locations before towing to
prevent damage to the transmission during towing due to insufficient
lubrication.
7.1.1 Releasing the parking brake mechanically

General
The spring-actuated parking brake is located in the same brake cham-
ber assembly as the service brake pneumatic chamber.
The spring-actuated parking brake is at the rear axle as standard,
Releasing the parking brake
Determine whether the chamber has an internal or external caging
tool.
With an externally mounted tool, first remove the access plug from
the brake canister. Insert the caging tool into the access hole and turn
it 1/4 turn to engage with the slot on the pressure plate. Try to pull the
caging tool out; it should not pull out.
After engaging the caging tool, or if the chamber has an internal ca-
ging tool, thread the nut and washer down onto the threaded end of
the caging tool all the way to the canister. Tighten the nut until the
threaded portion of the release tool is out. It should extend approxi-
Chamber with an external caging tool mately 7,5 centimeters out of the nut.
Release the front axle parking brake, if fitted, as described above.
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62 7 Transport of machine - 7.1.1 Releasing the parking brake mechanically
DANGER
Prior to releasing the parking brake mechanically,
ensure that the tractor cannot move by, for example,
chocking the wheels.
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7 Transport of machine - 7.2 Lifting and transporting machine 63
7.2 Lifting and transporting machine
General
Engage the parking brake and secure the tractor to the cargo bed with,
for example, chains so that the load cannot shift and cause hazard to
other road users and the tractor remains intact during transportation.
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64 7 Transport of machine - 7.3 Service position
7.3 Service position
General
The tractor service position is used while performing maintenance
procedures.
The tractor is in the service position when the following conditions
are met:
• The tractor is parked, and the parking brake is engaged.
• The main power is switched off with the main switch.
DANGER
Ensure that the fifth wheel is unloaded and the lift boom
is supported mechanically if it must be in the upper
position during maintenance or repair.
Prior to tilting the cab to the maintenance position,
ensure that the radiator grille at the front of the cab is
lifted up, the cab door is properly closed, and any loose
items are removed from the cab.
prohibited!
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7 Transport of machine - 7.4 Long-term storage 65
7.4 Long-term storage
General
If the tractor is to be stored for an extended period of time, contact the
manufacturer for detailed storage instructions.
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66 7 Transport of machine - 7.4 Long-term storage
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8 Environment 67
8 Environment
General
Increasing industrialisation has a significant effect on our environment
on a global scale. Nature, animals, and people are every day exposed
to risks caused by exposure to various chemicals.
In this light, the long-term objective is to develop chemicals that are
completely friendly to the environment. However, many chemicals in
current use, such as oils, greases, and coolants, are classified as
problem waste.
By using appropriate tools and procedures, we can reduce the impact
on the environment.
When the machine is serviced according to the maintenance plan de-
scribed in the service manual for this machine, the machine is safe for
the operator and places the smallest possible burden on the environ-
ment.
By observing the instructions that follow, you do your part in the con-
servation of our common environment.
Kalmar environmental policy

The management of environmental issues at China factory is based
on the manufacturers operational policy, to which this environmental
policy is a supplement.
Our operations are based on making continual improvements to pre-
vent pollution of the environment, and on developing environmentally
friendly products and services.
The operations of the factory are developed in accordance with the
principles of sustainable development.
Each year, the factory management looks at the main environmental
concerns, determines its environmental objectives and develops an
environmental management program to meet the objectives.
The management will keep track of the environmental objectives and
corrective actions by conducting internal audits as part of the opera-
tions system.
Reacting to possible environmental abnormalities and taking the nec-
essary corrective actions is the responsibility of the entire staff.
The China factory adheres to the current legislation and regulations
in its operations.
Our operations comply with the international environmental system
standard ISO 14001 and the principles of sustainable development
set by the International Chamber of Commerce.
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68 8 Environment
Environmental awareness
Aim to define your own environmental awareness. Ask your su-
pervisor for more training if required. After the training, make sure
that you can adapt the information received to your everyday
tasks. Product manuals also contain environmental information
about the product.
Ensure that you have sufficient general knowledge about the mat-
ters that have to do with your tasks. You can improve your product
knowledge by studying user manuals and spare parts lists provi-
ded by the manufacturer. The manufacturer will also provide the
necessary user training when needed. Find out about the envi-
ronmental and safety instructions for using, servicing and repairing
the machine. What is most important is to know how to act in ex-
ceptional cases. Follow the maintenance and adjustment sched-
ules carefully. Use the designated oils and other liquids. Check
that the oil levels are correct. In general, when using the machine,
make sure that it works properly and is in the appropriate condition
for the job.
Try to decrease emissions and the amount of waste produced as
best you can. Do not take any risks, work with care. Try to do the
right things in the right way.
Environmental problems
By environmental problems, we mean faults detected in machine
operation that will or might be harmful to the environment. The
most common of these are oil and other liquid spills, toxic waste,
leaks and fires. If seals on cabs are damaged or worn, this can
also lead to an environmental problem, in case it causes the op-
erator to be exposed to noise levels which are too high. If there
are possible environmental problems, immediately contact your
supervisor or the person responsible for environmental issues.
Continuous monitoring of the machine operation along with pre-
ventive maintenance and repairs ensures the safe and uninter-
rupted use of the product. Follow the maintenance instructions
diligently so as not to jeopardize the machine and its user. By
blocking up leaks and checking the joints and pipe installations,
you can ensure that no unwanted liquids are released from the
machine.
Laws and regulations

There are several laws and regulations that have to do with using
the machine. It is the employer’s responsibility to make sure the
requirements are met in the work. Environmental issues have be-
come increasingly important. It is important to be aware of the
current requirements, but it is equally important to follow up on the
changes in the requirements. The requirements tend to become
tighter all the time.
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8 Environment 69
Use of materials and energy

Reasonable and appropriate use of materials can yield surprisingly
high savings in costs and also decrease environmental load. Preven-
tive maintenance has a decisive influence on decreasing machine
downtime.
User and maintenance manuals are intended to teach how to use the
machine correctly and safely. Always use spare parts recommended
by the manufacturer, and perform maintenance and repairs in ac-
cordance with the instructions. Follow all fluid changing intervals. Use
environmentally friendly materials when possible. Also try and use re-
cycled materials. In this way, you will achieve the best possible results
both for the environment and safety.
When using a machine, energy consumption is most influenced by the
condition of the machine and the machine operator’s skills. The man-
ufacturer has installed and set the adjustable values of your machine
to the optimal level for both consumption and emissions. Regular
maintenance and immediate repair work when necessary are a pre-
requisite for optimal machine operation. Pay special attention to start-
ing the machine from cold and the instructions given for this.
Effects of exhaust gases

Diesel engine emissions are the cause of both health and environ-
mental problems. The most serious environmental problem is soil
acidification, which is manifested in problems in tree growth and plant
formation as well as eutrophication.
Of the diesel engine emissions, nitrous oxide (NOx) will form nitric acid
when coming into contact with water, and sulfur dioxide will form sul-
furic acid. Both of these are strong acids that have an effect on plant
formation by decreasing the ability of roots to absorb water and min-
erals.
Particles are primarily the result of poor combustion of the fuel-air
mixture in the diesel engine. They consist of small carbon particles
(<10 μm) on which toxic hydrocarbons have concentrated. These
come from the fuel and lubricating oil. The particles are released into
the air along with the exhaust gases and the mutagenic and carcino-
genic hydrocarbons may then enter human lungs.
Hazardous emissions are mainly the result of incorrect adjustment of
the motor and lack of maintenance. For this reason, it is essential that
adjustments and maintenance are as described in the instruction
manuals.
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70 8 Environment
Recycling
The primary goal of environmental protection is to decrease the
amount of waste produced. If waste is produced, you must try to
utilize it as a material or source of energy. Appropriate and safe
processing must be arranged for all kinds of waste. The sorting of
the waste created in our operations is influenced by the legislation,
environmental factors and general tidiness, among other things.
The amount of waste driven to the landfill can be decreased by
sorting the waste in the appropriate, labeled receptacles. The most
effective way of protecting the environment is to save material and
energy and use environmentally friendly methods and products.
Become familiar with the waste disposal and recycling instructions
of your unit.
Metal waste can be collected, sorted and delivered to the industry
for use as a raw material and alloying element. Recycling saves
approximately half of the energy that would be consumed if the
same amount of metal were obtained from a mine.
Toxic waste means waste that can be hazardous to health or the
environment because of some chemical or other property. When
collecting and handling toxic waste, these health and environmen-
tal risks need to be taken into account. Toxic waste typically in-
cludes batteries and accumulators, paints, solvents, other special
liquids, fuel waste, coolant waste, aerosols and used fluorescent
tubes. Sort all toxic waste and make sure it is treated appropriately.
Deliver the used or discarded materials (packing waste, clean
metal parts, electric components, etc.) to a recycling centre or an-
other suitable location to be destroyed.
Complete overhaul or disposal

As the lifetime of the machine draws to a close, there are two op-
tions for dealing with the machine: complete overhaul or disposal.
If complete overhaul is selected, use the manufacturer's expertise
to determine the amount of repairs needed. This also ensures that
any new environmental and safety requirements will be taken into
account. In the case of complete overhaul, the product needs to
be equipped to meet the new requirements. This is the responsi-
bility of the person conducting the repair work.
Environmental load can be reduced by sorting materials and com-
ponents. Please note that the machine mostly consists of various
iron structures, which are mainly recyclable.
As to the disposal of toxic waste, you must find out the appropriate
methods of disposing of the liquids, materials and components.
The safety bulletins of the various liquids and materials contain
instructions for disposal. You can also consult the suppliers of
components and the product manufacturer for disposal and sort-
ing.
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8 Environment 71
Problem waste
Deliver materials that are classified as problem waste, such as bat-
teries, used filters, plastic parts, and other problematic components,
to a problem waste collection point.
Discard the problem waste according to the laws and environmental
regulations that are in effect for the machine's operating environment.
Oils and fluids

The main consideration for the environment is to prevent oil and other
toxic liquids from entering ground water and surface water courses.
Even small oil spills can cause significant damage to water courses.
Pay attention to any possible spills on your machine. Make sure the
hoses are in good condition to prevent unpleasant surprises. When
there is a spillage, absorb the spilled oil in sawdust, for example, and
remove the contaminated sawdust according to your site instructions.
In case of an accident, immediately contact your supervisor or the
person responsible for environmental issues.
Use appropriate containers, an oil collection basin, a pump, a hose,
etc. when removing oils and other fluids from the machine. Let com-
panies specialising in recycling of problem waste take care of dis-
carding the used oils and other fluids.
Pay special attention to fluid leaks. If any oil has leaked onto the
ground, absorb this oil in sawdust or a similar material and deliver the
contaminated sawdust to the problem waste collection point.
Properly address the cause of the leak, and replace damaged parts
before carrying on working with the machine!
Air conditioning
The refrigerant of the cab's air conditioner accelerates the greenhouse
effect. Refrigerant must not be discharged from the air conditioning
system into the atmosphere.
NOTE
The air conditioning system must be serviced only by skilled
service personnel qualified to service refrigeration equipment.
Occupational health and safety

Pay attention to your working environment. Perform the necessary
maintenance and repair work to prevent sickness or accidents caused
by vibration, noise or other factors. Recognize the needs for safety
training, and get to know the safety bulletins of the hazardous sub-
stances you have to work with.
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72 8 Environment
Working in an environment that is

hazardous to the health
If the machine must be operated in an environment that poses
health hazards, the machine must be equipped, operated, and
serviced according to the laws and regulations established for
those conditions.
Environments that are hazardous to the health include premises
where asbestos particles or other dust fills the air.
When the machine has been used in such an environment, take
special care when discarding the cabin's and engine's air filters.
If the machine has been operated in environments such as those
mentioned above, the discarded filters must be kept in appropriate
waste containers and delivered to the problem waste collection
point.
Remember these:
Being tidy and systematic is the most important consideration.
Remember to:
- Act according to instructions
- Check that all liquids are filled correctly
- Check for leaks
- Make sure that everything is functioning correctly
- Return the tools used for maintenance and repair work to their
right place
- Store unused components appropriately
- Recognize environmental problems
- Sort the waste that is produced
- Clear up the environment after finishing work
- Keep the working areas, emergency exits and electric cabinets
clear and unobstructed
- Report all abnormal events
Contact your supervisor or the person responsible for environ-

mental issues if necessary. Keeping your own working environ-
ment tidy and in good order is your personal responsibility. Tidi-
ness and orderliness influence how the workplace functions, de-
crease the number of accidents at work, and contribute to the
positive image of the company and its employees.
Standards
Vibration affecting the hands
Measured at the steering wheel in accordance with standard SFS-
ENV 25349: the vibration affecting the hands does not exceed 2.5
m/s 2 at normal operation.
Vibration affecting the whole body
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8 Environment 73
Measured at the driver's seat in accordance with standard ISO 2631:

the vibration affecting the whole body when working with the terminal
tractor does not exceed 0.5 m/s 2 at normal operation.
Noise levels
Maximum noise level inside and outside the cabin complies with the
standard SFS-EN 12053 + AC.
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74 8 Environment
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9 Specifications 75
9 Specifications
General
This chapter includes the dimensional drawing of the terminal tractor,
a summary of component specifications and settings, and specifica-
tions for the recommended oils, fluids, and greases to be used in the
tractor.
At the end of the chapter there is a table of the most common units
and their abbreviations, as well as conversion tables for the SI units
and length, area, volume, weight, mass, and pressure measurements.
Dimensional drawing
Dimensions and weights marked with an asterisk can vary depending
on customer-specific specifications and equipment.
50[1274mm] 83[2110mm]
112[2843mm]
30[750mm]
50[1256mm]
96[2435mm] FRONT
115[2930mm] WHEELBASE
98[2477mm] REAR
192[4890mm] OAL
Specifications
Engine DongFeng Cummins QSB6.7-C220
Operating principle Turbocharged & air-to-air inter-cooled
Number of cylinders 6
Capacity 6.7 L
Power (ISO 3046, net) 164 kW / 2200 rpm
Torque (ISO 3046) 949 Nm / 1500 rpm
Engine speeds Idle speed 800 rmp
Alternator Voltage (V): 28; Current (A): 70

Starting batteries Voltage (V): 24; Current (A): 100
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76 9 Specifications
Transmission Allison 3500

Operating principle Automatic transmission with torque converter
Torque converter ratio 1.82
Gear ratios Gear 1: 4.59:1, gear 2: 2.25:1, gear 3: 1.54:1, gear 4: 1.00:1
Reverse 4.99:1
Axles
Front axle Hande Front axle
Spring Center Distance 920 mm
Toe-in 0-2 mm
King pin inclination (KPI) 7°
King pin caster 0°
Camber 1°
Brake size φ400 x 150 mm
Brake chamber 24"
Rear axle Hande Rear axle
Ratio and axle brake equipment are specified in the spare parts catalogue of this tractor.
Suspension
Front axle Semi-elliptic leaf-springs, attached with pivot pins to the tractor frame and with clamps to the
axle.
Rear axle On the standard tractors, the rear axle is bolted rigidly to the tractor frame.
Brakes
Operating principle Spring brake activates by means of spring mechanical force. During this process, air is not
necessary, but de- aeration is needed. When the driver engages the spring brake or when
the brake system air pressure drops below the set minimum pressure (43 P.S.I.), spring brake
will activates automatically. It is released by compressed air when air pressure is recovered
to certain value (70 P.S.).
Service brake Dual circuit drum brakes on four wheels.
Parking brake Spring-loaded drum brake at the rear axle, controlled with an pneumatic switch in the cab.
Steering
Steering system Hydraulic steering turning the front wheels.
Wheels
Tyre size, front/rear Standard 11.00 R22.5
Tyre pressure Depends on tyre model
Rim size, front/rear 8.25-22.5
Rated axle load Front 7,500 kg
Rear 32,000 kg
Fifth wheel Holland series

Maximum load 32,000 kg, based on type
Minimum height from the 1092 mm
ground
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9 Specifications 77
Lifting height 431.8 mm

Side tilting Passive tilting 3°.
Hydraulics
Operating principle The pressure and volume flow required by the terminal tractor hydraulic system is generated
by a fixed pump which is actuated by the PTO - on the transmission.
A priority valve is integrated in the pump and it primarily directs the pump output for the tractor
steering. The flow for the steering is determined by the load information coming from the
steering device. If steering is not in operation, no hydraulic oil flow is directed to the steering
cylinders.
Steering hydraulics pressure 100 bar
value
Working hydraulics pressure 138 bar with a lifting capacity of 28,000 kg, double-acting lift cylinders
values
Pneumatic system
Operating principle A compressor coupled to the engine generates the required volume flow for the pneumatic
system.
The pressure control valve at the compressor directs the compressor output to the by-pass
line when the system pressure exceeds 8.0 bar.
Compressor rating output 200 L/min
Compressor cylinder diameter 90 X 46
X stroke
Oil, grease, and fluid capacities

Engine
Lubrication system 17L~24L,based on Engine
Cooling system Water cooling system
Fuel tank 75 GAL
Transmission
Lubrication system 29.5 litres, Allison 3500, please based on transmission instruction
Axles
Front axle 0.6 + 0.6 litres, wheel hubs
Rear axle 18 litres, final drive and differential
1.5 + 1.5 litres, wheel hubs
Hydraulics
Hydraulic oil tank 60 litres (System: 79.5 litres)
Cab
Windscreen washer fluid reser- 4 litres
voir
Air conditioner About 900 g
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78 9 Specifications
Central lubrication system
Grease reservoir 2 kg
Recommended lubricants and

fluids
Service item Description API/ASTM/SAE/
ISO/Classifica-
tion
Engine lubrication system
Diesel engine oil SAE 15W-40 API CJ-4
YC6J
Ambient temperature
-15 °C - +45 °C
Engine cooling system 50 % high-quality monoethyleneglycol-based coolant and 50 % water. BS6580 (1992)
Please review engine instruction, it is different based on type. AFNOR (1991)
ASTM D 3306
NOTE
The coolant should be of antifreeze and antirust. Pure water is not
allowed to be filled into cooling system, and can't be topped up. Do
not to mix different coolants together.
During the normal operation, the outlet coolant temperature is
generally controlled to 80°C ~ 95°C, while the oil temperature is
generally controlled to 90°C~105°C. The max. Outlet coolant
temperature should not exceed 101 °C.
Transmission ALLISON C-4

Automatic transmission fluid (ATF)
Allison 3000
or
Ambient temperature
TranSynd / TES 295 fluid (The fluid change interval 3000 hours)
-30 °C - +30 °C
Axles GL-5, 75W/90, synthetic oil
GL-5
Hande
Front / rear axle gear lubricant
Ambient temperature
Front axle: 10 lbs; Rear axle: 30 lbs
-20 °C - +40 °C
Hydraulic oil tank Hydraulic oil ISO VG 32
Fuel tank High-quality diesel fuel EN590
Cab tilting pump Hydraulic oil ISO VG 32
Air conditioner
R134A
Refrigerant
Compressor oil
Windscreen washer fluid Isopropyl washer fluid
Fluid-water mix ratio 1:3 in winter, and 1:6 in summer
Frame, lift boom, and fifth wheel EP multipurpose grease, for example, ESSO Beacon EP1, MOBIL Mo- NLGI 1
grease lubrication points bilgrease HP222, Shell Alvania EP1, or CASTROL APS 2.
Temperatures
below -10 °C, use
NLGI 0
Operator's manual
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9 Specifications 79
Service item Description API/ASTM/SAE/

ISO/Classifica-
tion
Central lubrication system Multipurpose grease
Ambient temperature
Example:
-10 °C - +45 °C Shell Alvania EP1 NLGI 1
-15 °C - +10 °C Shell Alvania EP0 NLGI 0
-30 °C - -5 °C Central lubrication grease Shell Centra W NLGI 00
Units of measurement and their

abbreviations
Unit Abbreviation
Newton-metre Nm
Kilopond-metre kpm
Kilopascal kPa
Megapascal MPa
Kilowatt kW
Kilojoule kJ
British thermal unit Btu
Calorie ca
Inch in
Foot ft
Yard yd
Mile mile
Centimetre cm
Metre m
Kilometre km
Conversion table, SI units

SI unit Conversion factor Other than SI Conversion factor SI
Torque
Nm x 10.2 = kg·cm x 0.8664 = lb·in
Nm x 0.74 = lbf·ft x 1.36 = Nm
Nm x 0.102 = kg·m x 7.22 = lb·ft
Pressure (Pa = N/ m 2 )
kPa x 4.0 = in. H 2O x 0.249 = kPa
kPa x 0.30 = in. Hg x 3.38 = kPa
kPa x 0.145 = psi x 6.89 = kPa
bar x 14.5 = psi x 0.069 = bar
kp / cm 2 x 14.22 = psi x 0.070 = kp/cm 2
Operator's manual
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80 9 Specifications
SI unit Conversion factor Other than SI Conversion factor SI
N/ mm 2 x 145.04 = psi x 0.069 = bar
MPa x 145 = psi x 0.00689 = MPa

Power (W = J/s)
kW x 1.36 = hp (cv) x 0.736 = kW
kW x 1.34 = bhp x 0.746 = kW
kW x 0.948 = Btu/s x 1.055 = kW
W x 0.74 = ft·lb/s x 1.36 =W
Energy (J = Nm)
kJ x 0.948 = Btu x 1.055 = kJ
J x 0.239 = calorie x 4.19 =J
Speed and acceleration
m/s 2 x 3.28 = ft/s 2 x 0.305 = m/s 2

m/ s x 3.28 = ft/s x 0.305 = m/s
km/ h x 0.62 = mph x 1.61 = km/h
Horsepower/ torque
Bhp x 5252 rpm= TQ (lb·ft) TQ x rpm 5252 = bhp
Temperature
ºC = (ºF – 32)/1.8 ºF = (ºC x 1.8) + 32
Flow factor
l / min (dm 3 / min) x 0.264 = US gal / min x 3.785 = l/min
Conversion table, length

Unit cm m km in ft yd mile
cm 1 0.01 0.00001 0.3937 0.03281 0.01094 0.000006
m 100 1 0.001 39.37 3.2808 1.0936 0.00062
km 100000 1000 1 39370.7 3280.8 1093.6 0.62137
in 2.54 0.0254 0.000025 1 0.08333 0.02777 0.000015
ft 30.48 0.3048 0.000304 12 1 0.3333 0.000189
yd 91.44 0.9144 0.000914 36 3 1 0.000568
mile 160930 1609.3 1.6093 63360 5280 1760 1
1 mm = 0.1 cm, 1 mm = 0.001 m
Conversion table, area

Unit cm 2 m2 km 2 a ft 2 yd 2 in 2
cm 2 1 0.0001 - 0.000001 0.001076 0.000012 0.155000
m2 10000 1 0.000001 0.01 10.764 1.1958 1550.000
km 2 - 1000000 1 10000 1076400 1195800 -
a 0.01 100 0.0001 1 1076.4 119.58 -
Operator's manual
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9 Specifications 81
Unit cm 2 m2 km 2 a ft 2 yd 2 in 2
ft 2 - 0.092903 - 0.000929 1 0.1111 144.000
yd 2 - 0.83613 - 0.008361 9 1 1296.00
in 2 6.4516 0.000645 - - 0.006943 0.000771 1
1 ha = 100 a , 1 mile 2 = 259 ha = 2.59 km 2
Conversion table, volume

Unit cm 3 = cc m3 l in 3 ft 3 yd 3
cm 3 = ml 1 0.000001 0.001 0.061024 0.000035 0.000001
m3 1000000 1 1000 61024 35.315 1.30796
dm 3(l) 1000 0.001 1 61.024 0.035315 0.001308
in 3 16.387 0.000016 0.01638 1 0.000578 0.000021
ft 3 28316.8 0.028317 28.317 1728 1 0.03704
yd 3 764529.8 0.76453 764.53 46656 27 1
1 gal (US) = 3785.41 cm 3 = 231 in 3 = 0.83267 gal (UK)
Conversion table, mass

Unit g kg t oz lb
g 1 0.001 0.000001 0.03527 0.0022
kg 1000 1 0.001 35.273 2.20459
t 1000000 1000 1 35273 2204.59
oz 28.3495 0.02835 0.000028 1 0.0625
lb 453.592 0.45359 0.000454 16 1
1 ton (metric) = 1.1023 ton (US) = 0.9842 ton (UK)
Conversion table, pressure

Unit kp/cm 2 bar Pa=N/m 2 kPa lbf/in 2 lbf/ft 2
kp /cm 2 1 0.98067 98066.5 98.0665 14.2233 2048.16
bar 1.01972 1 100000 100 14.5037 2088.6
Pa=N/ m 2 0.00001 0.001 1 0.001 0.00015 0.02086
kPa 0.01020 0.01 1000 1 0.14504 20.886
lbf/in 2 0.07032 0.0689 6894.76 6.89476 1 144
lbf/ft 2 0.00047 0.00047 47.88028 0.04788 0.00694 1
kg/cm 2 = 735.56 Torr (mmHg) = 0.96784 atm
Operator's manual
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82 9 Specifications
Operator's manual
1328 0 eng 2012-05-15
83
Index
.
About the documentation kit 7
About the Operator's manual 5
Brakes 40
Charging system for the batteries 51
Control lever 28
Cooling system 51
Daily inspection 46
Daily inspections 35
Description 13
Diagnostics 26
Engine air filter 52
Engine and transmission lubrication systems 50
Environment 67
Foreword 5
Fuel system 52
Gear and multi-function lever 24
Handling 33
Handling error codes 36
Heating / Air conditioning 31
Hydraulic system 53
Ignition 22
Inspection and maintenance 8
Inspection and maintenance 45
Instruments and controls 17
Lifting and transporting machine 63
Load handling 42
Long-term storage 65
Main components 13
Maintenance 48
Oil level and diagnostic 24
Operating 37
Operator's seat 30
Overview 13
Parking brake 41
Pedals 29
Reading the manual 5
Releasing the parking brake mechanically 61
Running-in 34
Safety 9
Safety and warning equipment 10
Selecting driving direction and gear 40
Service 54
Service position 64
Specifications 75
Starting the engine 38
Steering 40
Stopping the engine / parking 41
Towing 61
Transporting a trailer 42
Transport of machine 61
Warning symbols 36

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TL165

4. Instruments and controls .................................................................................................... 17

6. Inspection and maintenance ............................................................................................... 45

7. Transport of machine ........................................................................................................... 61

1.1.1 Reading the manual

1.2 About the documentation kit

If extra copies of instruction manuals or the spare parts catalogue for

Ordering the manuals

1.3 Inspection and maintenance

• Notify your superior or the person responsible for the maintenance

2.1 Safety and warning equipment

Tilting the cab for maintenance

Belts and driveshafts

Fifth wheel and lift boom

3.1.1 Main components

Hydraulic oil tank

Location of controls in the cab

Side dashboard panel

Fifth wheel control

Fifth wheel unlatch button

High beam Heater air intake

Right turn Low battery

Low air Low fuel level

Check engine Low oil pressure

Check transmission Low engine water level

Power on Power from the batteries to the electric devices is on.

Ignition key lock

Starting the engine

2 Place the transmission control in neutral.

Stopping the engine

4.5 Gear and multi-function lever

About selecting driving direction and gear

Driving direction selector

4 2. Driving direction - Neutral

4.5.1 Oil level and diagnostic

2 Press the UP and DOWN arrow buttons simultaneously.

The indication of delayed fluid level check for pushbutton and

4 The shift selector displays the oil level as follows:

If there is a measuring fault, measuring is interrupted and the display

5 Press any range button to exit oil level display mode.

2 Press the UP and DOWN arrow buttons simultaneously twice.

3 Press any range button to exit oil level display mode.

4.6 Control lever

Fifth wheel control

Backward The fifth wheel is raised.

4.9 Operator's seat

About the seat

Item 1 Back angle adjustment.

4.10 Heating / Air conditioning

Cab heating system

Adjusting the heating and air conditioning

5.2 Daily inspections

5.3 Handling error codes

5.3.1 Warning symbols

5.4.1 Starting the engine

Main switch (A)

Ignition key lock

Starting the engine

If the engine is fitted with an engine block heater to ensure starting in

Starting with auxiliary batteries

5.4.2 Selecting driving direction and gear

5.4.5 Parking brake

5.4.6 Stopping the engine / parking